Boeing 787

from the
Ground Up

qtr_04

06
a quarterly publication
boeing.com/commercial/
aeromagazine
 The 787 Dreamliner
takes advantage
of new technologies
to increase reliability and
improve maintainability.

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Boeing 787
from the Ground Up

by Justin Hale,
787 Deputy Chief Mechanic

With the 787 Dreamliner, Boeing is using a new approach to

design which takes into greater account the cost to maintain
airplane structure and systems over their lifetimes. As a result
of this approach, the basic 787-8 airplane will have 30 percent
lower airframe maintenance costs than any comparable product
and will be available for revenue service more often than any
other commercial airplane.

The Boeing 787 program has consciously
designed in new, state-of-the-art features and
performance that reduce cost and increase
airplane availability. These features will lead to
additional savings and greater revenue for Boeing
customers. The 787 reflects a new life-cycle
design philosophy that has dictated some
significant changes in the way the airplane will be
built. These changes include extensive use of
composites in the airframe and primary structure,
an electric systems architecture, a reliable and
maintainable design, and an improved
maintenance program. Taken together, these
changes will offer customers a guaranteed
reduction in maintenance costs.
Life-cycle cost design philosophy
The life-cycle cost approach to design looks at the
total cost picture for design options by examining
all of the factors that affect an airplane over its
lifetime. Traditionally, the value of a given design
solution has been measured using factors such as:
n Drag
n Weight
n Noise (cabin and community)
n Schedule reliability
n Development cost
n Build cost
Using these measures to compare design
options helps determine the optimum choice.
With the 787, Boeing has expanded the life-
cycle design approach by adding two unique
performance measures: maintenance cost and
airplane availability. Clearly, looking at the cost to
maintain systems over their lifetimes becomes a
significant factor when attempting to understand
the total effect of a design decision on an operator’s
cost structure. Airplane availability includes not
only schedule reliability but also other factors such
as the length of time an airplane must be out-of-
service when maintenance is required. Obviously,
taking an airplane out of service for two days has a
much bigger effect on operator revenue than
taking it out of service for two hours.

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 Composites in the airframe and
primary structure
The Boeing 787 makes greater use of composite
materials in its airframe and primary structure than
any previous Boeing commercial airplane. Under­
taking the design process without preconceived
ideas enabled Boeing engineers to specify the
optimum material for specific applications
throughout the airframe.
The result is an airframe comprising nearly
half carbon fiber reinforced plastic and other
composites. This approach offers weight savings
on average of 20 percent compared to more
conventional aluminum designs.
Selecting the optimum material for a specific
application meant analyzing every area of the
airframe to determine the best material, given the
operating environment and loads that a component
experiences over the life of the airframe. For
example, aluminum is sensitive to tension loads but
how composite solutions are
applied throughout the 787
50%
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handles compression very well. On the other hand, considerations indicate aluminum is a poor choice,
composites are not as efficient in dealing with titanium is an excellent low-maintenance design
compression loads but are excellent at handling solution. Titanium can withstand comparable loads
tension. The expanded use of composites, especially better than aluminum, has minimal fatigue con­
in the highly tension-loaded environment of the cerns, and is highly resistant to corrosion. Titanium
fuselage, greatly reduces maintenance due to fatigue use has been expanded on the 787 to roughly
when compared with an aluminum structure. This 14 percent of the total airframe. Every structural
type of analysis has resulted in an increased use element of the 787 has undergone this type of life-
of titanium as well. Where loading indicates metal cycle analysis and material types are based on a
is a preferred material system but environmental thorough and disciplined selection process.
In addition to using a robust structural design
in damage-prone areas, the 787 has been designed
with the capability to be repaired in exactly the
same manner that airlines would repair an airplane
today — with bolted repairs. These can be just as
permanent and damage tolerant as they are on
a metal structure.
5% Other
Advanced Composites
20% Aluminum
Titanium
15%
10% Steel (primarily landing gear)
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 In addition to lowering the overall airplane
weight, moving to a composite primary structure
promises to reduce both the scheduled and
nonroutine maintenance burden on the airlines.
Reduced scheduled maintenance.  Experi­ence
with the Boeing 777 proves that composite struc­tures
require less scheduled maintenance than noncom­
posite structures. For example, the 777 composite
tail is 25 percent larger than the 767’s aluminum
tail, yet requires 35 percent fewer scheduled
maintenance labor hours. This labor hour reduction
is due to the result of a reduced risk of corrosion
and fatigue of composites compared with metal.
Reduced nonroutine maintenance.  A com­
posite structure also results in less nonroutine
maintenance. The 777 floor structure is all
composite and highlights the advantages of
this material when applied in a harsh environ­
ment. Airline operators are aware of the fatigue
cracking and corrosion difficulties experienced
boeing.com/commerc i a l / a e r o m a g a z i n e
with traditional aluminum floor beams. The 777
model has been flying for more than 10 years with
more than 565 airplanes in the fleet and to date
has not replaced a single composite floor beam.
Boeing has also implemented a rigorous
process for evaluating the use of aluminum that
combines likelihood of corrosion with consequence
of corrosion. This scoring system provides a
definitive measure for establishing acceptable
application of aluminum in the design with full
understanding of the maintenance implications.
Corrosion and fatigue in a structure add
significantly to the nonroutine maintenance burden
on an operator. Nonroutine maintenance frequently
doubles or even triples the total labor hours
expended during a maintenance check. With
the expanded use of composites and titanium
combined with greater discipline in usage
of aluminum, Boeing expects the 787 to have
much lower nonroutine labor costs than a more
conventional metallic airframe.
In addition to using a robust structural design
in damage-prone areas, such as passenger and
cargo doors, the 787 has been designed from the
start with the capability to be repaired in exactly
the same manner that airlines would repair an
airplane today — with bolted repairs. The ability to
perform bolted repairs in composite structure is
service-proven on the 777 and offers comparable
repair times and skills as employed on metallic
airplanes. (By design, bolted repairs in composite
structure can be permanent and damage tolerant,
just as they can be on a metal structure.)
In addition, airlines have the option to perform
bonded composite repairs, which offer improved
aerodynamic and aesthetic finish. These repairs
are permanent, damage tolerant, and do not
require an autoclave. While a typical bonded
repair may require 24 or more hours of airplane
downtime, Boeing has taken advantage of the
properties of composites to develop a new line of
maintenance repair capability that requires less
The right material for the
right application. Without
preconceived ideas, Boeing
engineers were able
to specify the optimum
material for specific
applications throughout
the airframe.
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 Bleed-Air Powered

no bleed / more electric UNAFFECTED pneumatic components

architecture SYSTEMS: removed from the engine and APU:

Engine anti-ice system Precooler

Pneumatic starter
Valves
Ducts
APU load compressor

The transition from

bleed‑air power to an
electric architecture
reduces the mechanical
complexity of the 787.

than an hour to apply. This rapid composite repair
technique offers temporary repair capability to get
an airplane flying again quickly, despite minor
damage that might ground an aluminum airplane.
In total, the reduced risk of corrosion and fatigue
associated with composites combined with the com­
posite repair techniques described will lower overall
maintenance costs and maximize airline revenue by
keeping airplanes flying as much as possible.
One innovative applica­
tion is the move from
No-bleed, more electric
systems architecture
The Boeing 787 reflects a completely new
approach to onboard systems. Virtually everything
that has traditionally been powered by bleed-air
from the engines has been transitioned to an
electric architecture. The affected systems include:
n Engine start
n Auxiliary power unit (APU) start
n Wing ice protection
n Cabin pressurization
n Various ducts, valves, and air control systems
n Leak and overheat detection systems
Auxiliary power unit.  The APU provides an
excellent illustration of the ben­efits of the more-
electric architecture. One of the primary functions
of a conventional APU is driving a large pneumatic
load compressor. Replacing the pneumatic load
compressor with starter generators results in
significantly improved start reliability and power
availability. The use of starter generators reduces
maintenance requirements and increases reliability

n Hydraulic pumps
due to the simpler design and lower parts count.

hydraulically actuated The only remaining bleed system on the 787

In terms of inflight start reliability, the 787 APU
is expected to be approximately four times more
brakes to electric. is the anti-ice system for the engine inlets. reliable than conventional APUs with a pneumatic

Electric brakes signi­ While much can be said regarding the efficiency
gains achieved by changing the means of extracting
load compressor.

ficantly reduce the power for airplane systems from the engines, the
Electrical power generation.  Another funda­
men­tal architectural change on the 787 is the use
mechanical complexity 787’s no-bleed architecture brings with it some sig­
nificant maintenance cost and reliability advantages
of variable frequency electrical power and the

of the braking system and as well. By eliminating the pneumatic systems from
integration of the engine generator and starter
functions into a single unit. This change enables
eliminate the potential the airplane, the 787 will realize a notable reduction
in the mechanical complexity of airplane systems.
elimination of the constant speed drive (also known

for delays associated with The list below highlights just a few of the compo­
as the integrated drive generator, IDG), greatly
reducing the complexity of the generator. In addi­
leaking brake hydraulic nents eliminated as a result of this systems change:
tion, by using the engine generator as the starter

fluid, leaking valves, and n

n
Pneumatic engine and APU start motors
APU load compressor
motor (an approach used with great success on the
Next-Generation 737 APU), the 787 has been able
other hydraulic failures. n Precoolers to eliminate the pneumatic starter from the engine.
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 ELECTRIC

pneumatic components AFFECTED

removed from the airframe: SYSTEMS:

Ducts APU start

Valves Brakes
Heat shields Cabin pressurization
Overheat monitoring systems Engine start
Duct burst protection systems Hydraulic pumps
Wing ice protection

When compared to the more complex 767 IDG, the
787 starter generator is predicted to have a mean
time between faults (MTBF) of 30,000 flight hours
— a 300 percent reliability improvement compared
to its in‑service counterpart.
Brakes.  One innovative application of the more-
electric systems architecture on the 787 is the
move from hydraulically actuated brakes to
electric. Electric brakes significantly reduce the
mechanical complexity of the braking system and
eliminate the potential for delays associated with
leaking brake hydraulic fluid, leaking valves, and
other hydraulic failures. Because its electric brake
systems are modular (four independent brake
actuators per wheel), the 787 will be able to
dispatch with one electric brake actuator (EBA)
inoperative per wheel and will have significantly
reduced performance penalties compared with
dispatch of a hydraulic brake system with a failure
present. The EBA is line-replaceable enabling
in‑situ maintenance of the brakes.
In general, electric systems are much easier
to monitor for health and system status than
hydraulic or pneumatic systems; the brakes take
full advantage of this. Continuous onboard
monitoring of the brakes provides airlines with a
number of advantages, such as:
boeing.com/commerc i a l / a e r o m a g a z i n e
n Fault detection and isolation
n Electrical monitoring of brake wear
n Ability to eliminate scheduled visual brake
wear inspections
n Extended parking times
Because the 787 brakes can monitor the
braking force applied even while parked, the
electric brakes enable extended parking brake
times by monitoring and automatically adjusting
its parking brakes as the brakes cool.
At an airplane level, the reduction in
systems parts by moving to a primarily electric
architecture is significant. Overall, the 787 will
reduce mechanical systems complexity by more
than 50 percent compared to a 767; elimination
of pneumatic systems is a major contributor.
As a consequence of this reduction in complexity,
airlines will experience reduced airplane-level
maintenance costs and improved airplane-level
dispatch reliability.
In fact, the move to electric systems is expected
to cut about a third of the schedule interrupts com­
pared to a 767 for the systems affected by the
no-bleed/more-electric architecture. Other benefits
include improved health monitoring, greater fault
tolerance, and better potential for future tech­
nology improvements.
Overall, the 787 will
reduce mechanical
systems complexity by
more than 50 percent
compared to a 767; the
elimination of pneumatic
systems is a major
contributor.
Reliable and maintainable by design
In addition to major changes such as use of com­
posites and the elimination of pneumatic systems,
the 787 takes advantage of new technologies to
increase reliability and improve maintainability.
Boeing has looked for opportunities large and
small to reduce maintenance costs while making
the 787 highly available for revenue service.
Here are some wide-ranging examples that
illustrate the extent of these improvements.
Advanced maintainability analysis.  A new
generation of digital analysis tools is enabling
Boeing to better understand future maintenance
issues during the design process. Through
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 ELECTRO-CHROMATIC
DIMMABLE WINDOWS:

Eliminated mechanical window shades

High reliability – 70,000 cycles / 20 years
Operational temperature range -40C – +60C
Installed between the dust cover and outside window
Easily replaced by removing window reveal

animated simulations, designers ensure mechanics
can perform various procedures effectively and
efficiently, resulting in a more maintainable
airplane and higher quality maintenance
procedures. Boeing has already identified about
4,000 areas of maintenance on the airplane
and will both digitally and physically validate
100 percent of 787 maintenance procedures
prior to entry into service (EIS).
Advanced maintenance computing
systems.  The 787 features greatly expanded and
improved systems monitoring capability coupled
with an advanced onboard maintenance computing
system. This capability combined with e-enabling
technologies, which make real-time ground-based
monitoring possible, will significantly aid in rapid,
accurate troubleshooting of the 787. Airplane
systems information used in conjunction with fully
integrated support products will help maintenance
and engineering organizations quickly isolate
failed components and reduce return-to-service
times. Boeing expects the 787 to show a reduction
in no-fault-found (NFF) removals of 58 percent
compared to the 767, reducing yet another major
cost driver for 787 operators.
Selective paint stripping.  Boeing is pioneering a
new paint stripping technique that makes it possible
to chemically strip the paint on the airplane’s
composite airframe. A three-hour chemical strip
removes decorative paint. This eliminates the
hand-sanding requirement for paint removal on
composite structure and puts the 787 on par with
a metal airplane in terms of repaint times.
Electro-chromatic dimmable windows.  emitting diode (LED) lighting.  The 787
The 787 replaces mechanical window shades
with highly reliable electro-chromatic dimmable
windows with a projected life of more than
20 years. In addition to eliminating the
maintenance associated with light-leaking or
inoperable window shades, electro-chromatic
dimmable windows give cabin crews the ability to
dim or brighten an entire cabin at the press of a
single button.
Propulsion structure and airplane interface. 
The 787 marks the first time Boeing has made the
engine type interchangeable at the wings. That
allows a 787 owner to quickly and easily convert
an airplane to a different engine brand in order to
place it into a fleet. The 787 engine cowlings have
a quick composite repair capability, enabling small
damages to be repaired in one hour at the gate,
maximizing the airplane’s availability.
High-intensity discharge (HID) and light
has replaced virtually all cabin, flight deck and
exterior lighting with HID and LED lighting technolo­
gies. Because these light types have no filament,
the operational life of the lights is dramatically
longer than that of an incandescent bulb. For
example, HID landing lights will last an order of

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 Cumulative
maintenance-
planning
data (MPD)
document
labor hours
OVER 25 YEARS

■  767-300 ER
■  787-8

A CHECK C CHECK D CHECK/HMV

44% 65% 63%

reduction reduction reduction

Improved and expanded monitoring, advanced onboard

maintenance systems, and e-enabling technologies make
real‑time ground-based monitoring possible. This will aid
in troubleshooting the 787. Airplane systems information and
fully integrated support products will help maintenance and
engineering organizations quickly isolate failed components
and reduce return-to-service times. Boeing expects the 787 to
show a reduction in NFF removals of 58 percent compared to the
767, reducing yet another major cost driver for 787 operators.

magnitude longer than the lights in service today.
LED cabin lights will last 50,000 operational hours
and LED aircraft position lights 20,000 operational
hours. Overall, 787 lights will last ten to twenty
times longer than their in-service counterparts.
Improved dispatch reliability.  In the 787,
Boeing is demonstrating that generational
improvements in systems technology result in
airplane-wide reliability improvements. At an
airplane level, component reliability is improved by
more than 15 percent when compared to the 767.
That translates into improved schedule reliability.
The 787 program is targeting a mature schedule
reliability of more than 99 percent.
Maintenance program development
By working closely with airlines, major partners
and suppliers, and regulatory agencies, Boeing
plans to deliver a scheduled maintenance program
approved by the U.S. Federal Aviation Administra­ Summary
tion and European Aviation Safety Agency before
taking the 787 into flight testing. The 787 program By designing the 787 with features and
has set target intervals for EIS that exceed those of performance that reduce cost and increase
any other commercial airplane. These target airplane availability, Boeing is developing an
intervals include a first external visual inspection of airplane that promises to offer Boeing customers
the structure at 6 years and the first internal visual significant savings and greater revenue.
inspection of the structure (heavy check) at 12 For more information, contact Justin Hale
years. The 787 maintenance program is on track at justin.e.hale@boeing.com. 
to deliver the target intervals at EIS.
In addition to longer intervals between
scheduled maintenance checks, the 787 program
projects labor hours content will be reduced by
20 percent on a per-check basis and total scheduled
labor hours will be reduced by 60 percent over the
life of the airplane.
This reduction in required scheduled
maintenance is another significant contributor
to the overall 30 percent airframe and systems
maintenance cost reduction guaranteed by the 787.

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